Adjustable terminal for shade rollers



A ril 25, 1%?

J. A. ANDERSON ET AL 3,315,728

ADJUSTABLE TERMINAL FOR SHADE ROLLERS Filed Sept. 10, 1965 ATTORNEYSUnited States Patent 3,315,728 ADJUSTABLE TERMINAL FOR SHADE ROLLERSJames A. Anderson, Muskegon, and Jacob A. Ash, Muskegon Heights, Mich.,assignors to Breneman-Hart: shorn, Inc., Cincinnati, Ohio, a corporationof Ohio Filed Sept. 10, 1965, Ser. No. 486,455 Claims. (Cl. 160326) Thisinvention relates to rollers for window shades and the like, and moreparticularly to a removable terminal plug to be used at one end of suchrollers and which provides for easy and rapid adjustment in theeffective length of the shade roller in predetermined and definiteincrements.

Window shades and the rollers upon which they are mounted are generallyproduced in several standard lengths, which are chosen to accommodatethose window widths which are most frequently encountered. A chronic andwidespread problem arises in this area due to the fact that a great manywindows are not of the standard widths. Also, the shade mountingbrackets which have been installed upon windows which are nominally of astandard width frequently vary somewhat from the true standard dimensionof the shade roller. Thus, actual experience indicates that more oftenthan not, adjustments in the effective overall length of a roller mustbe made before the shade can be mounted to the actual width of aparticular window.

Normally, the dealer from which the shade is purchased makes theadjustment in its length by selecting the next larger standard size ofshade which he has in stock and trimming both the shade and its rollerto the required dimension. In most instances, the dealers are equippedwith special machines for the trimming operation, but due to the manypossible sources of human error in the measurement and trimming, itfrequently occurs that the resultant shade roller does not accuratelyfit the window for which it was intended, and instead is cut somewhatshort of the precise size which is needed. It also frequently occursthat particular windows which appear upon casual examination andmeasurement to be of a standard size are actually a small amount(typically, one-eighth inch to one-half inch) wider than the nominalstandard dimension. In the many instances which both of these casesprecipitate, it is necessary for the consumer himself to somehowslightly adjust the length of the roller to meet the exact circumstanceswhich he encounters when he attempts to mount it for use. Accordingly,in order to completely provide for a satisfactory installation, shaderollers should provide a means by which their length may easily beextended or reduced over a relatively small range.

One answer to the problem of shade roller length adjustment is toprovide a removable terminal plug for the gudgeon pin end of the roller.Such a plug may be removed to permit trimming of the roller to differentlengths, and it will also provide for length adjustment of the rollerassembly if the extent to which the plug is inserted in the end of theroller may be varied over a given range. Various schemes have previouslybeen suggested also for varying the insertion of such plug and forsecuring the plug within the roller at its various inserted positions,since this of course is definitely required for satisfactoryperformance. However, most such previous schemes have had inherentlimitations which adversely affected their operation and made them lessthan tot-ally desirable. For example, the plug would tend to slipbackward into the roller when placed in an extended position, and theadjustment of the plug within the roller would be difiicult or extremelytedious. Further, removable and adjustable terminal plugs themselvescreate an annoying and bothersome problem, caused by inadvertentlydropping the roller upon its plug end. This seems to regularly andfrequently occur, and in the case of most removable terminal plugs itresults in the plug being forceably driven completely within the end ofthe shade roller tube in which it is inserted. This can occur eitherduring shipping, handling by the dealer, or handling by the consumersubsequent to purchase. Whenever it does occur, the result is that theterminal plug is extremely difficult to remove from the shade roller,since it wedges tightly within it in a position which is not accessiblefrom the outside. The roller tube itself may be damaged by either theforcible insertion of the plug thereinto or by attempts at removing theplug, and this is also likely to damage the plug, in that the gudgeonpin may be inadvertently removed, or structural damage to the pin or theplug itself may occur.

Accordingly, it is a major objective of the present invention to providea removable terminal plug for shade rollers which offers a unique anddesirable solution of the problems indicated above. The shade rollerassembly utilizing the present terminal plug may he quickly andextremely easily adjusted in length by fixed and definite incrementalamounts. Further, in any of its adjusted positions the shade roller iscompletely stable, since each adjusted position is positively indexedagainst inadvertent changes resulting from subsequent use. Also, eachindividual adjustment is substantially separate from and in dependent ofother similar adjustments, so that the shade roller may be readjusted atany desired time with the same ease and convenience as the first suchadjustment. The adjustable shade roller of the invention further includes a unique structure which is cooperative with the terminal plugfor positively preventing the forcible insertion of the plug completelywithin the tubular end of the shade roller at any stage in its shipmentand subsequent handling, and at any given adjusted position of theterminal plug.

The invention provides a shade roller assembly which may be quickly andeasily adjusted in length and which makes the fullest possible use ofexisting shade roller structures, so as to be comparatively inexpensiveand very attractive commercially. The adjustments in length may readilybe made by even unskilled persons, and Without the use of special tools.Further, these advantages are obtained by a structure which iseconomically feasible within a highly competitive, close margin industrysuch as is true in the manufacture of shade rollers.

The foregoing major objectives and the purposes and advantages lyingtherein, together with others which are equally a part thereof, will beunderstood by those skilled in the shade roller and shade rollerequipment art upon further consideration of the following specificationand its appended claims, particularly when taken in conjunction with theaccompanying illustrative drawings setting forth preferred embodimentsof the invention.

In the drawings:

FIG. 1 is a frontal perspective view of the terminal plug of theinvention;

FIG. 2 is an enlarged, transverse, sectional elevation taken through theplane 11-11 of FIG. 1;

FIG. 3 is a developed view of the body portion of the terminal plug ofFIGS. 1 and 2;

FIG. 4 is a fragmentary, lateral, perspective view of the open tubularend of the preferred shade roller for use with the terminal plug;

FIG. 5 is an enlarged, end elevation of the shade roller of FIG. 4,showing in phantom the terminal plug in engagement therewith;

FIG. 6 is a fragmentary, central section showing a first engagement ofthe terminal plug and the shade roller; and

FIG. 7 is a fragmentary, central section showing a secand engagement ofthe terminal plug and shade roller.

Briefly stated, the present invention provides an adjust able shaderoller assembly which includes a shade roller of the type having an opentubular end, means associated with the tubular roller defining a stopstructure therewithin, and a removable terminal plug which is insertableinto the tubular end of the roller. The terminal plug has a plurality ofrecesses formed therein which extend lengthwise of the plug from the endthereof which is inserted into the roller tube, and these recessesdiffer in length or extent from each other by predetermined incrementalamounts. Each such recess is arranged to be alignable with the stopstructure formed in the roller tube and to pass over the same when theplug is inserted into the roller, and each of the recesses terminates inan end wall which comes into abutting contact with the stop structure tolimit the tele copic engagement of the plug within the roller. Thus, theoverall length of the roller assembly may be varied merely byrealignment of the recesses in the plug relative to the stop structurewithin the tubular roller, and by insertion of the plug in this positionto the full extent limited by the noted abutting contact.

Referring now in more detail to the drawings, the terminal plug of theinvention has a generally cylindrical body portion 12 and an endstructure 14 which includes a gudgeon pin 16 for rotatably mounting theterminal plug and the shade roller associated therewith. The specificform of the end portion which is used to close the cylindrical body 12is not actually a part of the present invention, and the preferred end14 illustrated in the figures is specifically described and claimed inmy previous application Ser. No. 430,127, filed Feb. 3, 1965, andconsequently will not be described in detail here. The basicconstruction of the preferred body portion 12 of the terminal plug is oftubular sheet metal having a lap joint which is indicated generally at18. This general form of tubular construction is also set forth in theabove-noted earlier patent application and need not be specificallydescribed here, except to note that it includes circumferentiallyslideable interlocking means 19 and 20, by which the cylindrical body iscontractible to vary its effective diameter.

The basic point of departure of the present invention is theconfiguration of the outer periphery or surface of the cylindrical plugbody 12. This is best illustrated in FIGS. 1, 2, and 3, from which itwill be noted that the outer periphery of the body is fluted. That is, aregular series of evenly spaced grooves or recesses 22-36 inclusive areformed longitudinally of the body and extend toward the end portion 14from the opposite end of the plug, which is inserted into the tubularend of the shade roller. As the developed plan view of FIG. 3 clearlyillustrates, the flutes or grooves differ from each other in length,with each succeeding groove being preferably about one-eighth inchlonger than the next previous groove. Thus, if eight grooves areprovided as shown in the preferred embodiment of the figures, thedistance from the end of the shortest groove (i.e., groove 28) to theend of the longest groove (i.e., groove 26) will be seven-eighths inch.

Each groove or recess in the plug body may conveniently have the samewidth and cross sectional shape (see FIG. 2), and each groove terminatesin an end wall structure, to be seen subsequently in greater detail,except for the longest groove 26, which terminates directly adjacent therearward edge of the end portion 14 (see FIG. 1). Although notabsolutely a necessity, it is very convenient to locate the longestgroove 26 directly over the lap joint 18, as FIG. *3 illustrates, withone longitudinal half of this groove formed adjacent the lap jointinterlocking means 19 and 20 and the other longitudinal half of groove26 formed adjacent a lap joint flange 18a, such that when theinterlocking means are slidably inserted through the apertures formed inthe said flange, both halves of the groove will be placed adjacent eachother to form the finished groove 26 which is seen in FIGS. 1 and 2.

It will be observed that the surface of the body portion 12 connectinggrooves 28 and 30, connecting grooves 30 and 32, connecting grooves 36and 22, and connecting grooves 22 and 24 is cut away, as seen at 38, 40,42 and 44 of FIG. 3, with portions 38 and 42 extending approximatelyone-eighth inch from the adjacent end of the body, and portions 40 and44 extending approximately onefourth inch therefrom. The purpose forthis will also be seen subsequently.

The shade roller 46 which is most prefer-red for use with the terminalplug of the present invention preferably has an open tubular end formedby a rolled sheet metal construction, as seen in FIGS. 4 and 5. Thesheet metal forming the roller 46 is joined along a longitudinal lockseam 48 in a known manner, such that the seam extends inwardly from thesurface of the roller to form a ridge therewithin. Further, the walls ofthe tubular roller are lanced in diametric opposing fashion, to providea pair of inwardly-directed tabs 50 and 52 (FIG. 5) whose free endsextend toward the open end of the roller tube, at an acute angle to thesides of the tube. The tabs 50 and 52 are each positioned a distancefrom the open end of the tube that is equal to a selected fraction ofthe total length of the body portion 12, preferably the length of thegroove or recess 22.

In assembly and use, the cylindrical body 12 of the terminal plug isinserted into the open end of the shade roller tube 46, such that apreselected one of the flutes or grooves in the body is aligned with andpasses over the longitudinal lock seam 48 within the roller. The normaldiameter of the body portion 12 is preferably slightly greater than theinside of the roller tube, such that the plug must be slightlycontracted at its lap joint in order to be inserted into the tube. Inthis manner, the inherent resilience of the rolled plug exerts aconstant outward force against the inside of the tube to more securelyhold the plug in place therewithin.

As has been stated, each of the flutes terminates in an end wall. Thus,the extent to which the terminal plug may be inserted into the tube isdetermined by the length of the particular flute which is aligned withthe seam in the roller. This is illustrated in FIGS. 6 and 7, whereflutes 22 and 34, respectively, are seen engaged with the seam 48. Itwill here be seen that the end of the seam comes into direct abuttingcontact with the end walls 220 and 34a of grooves 22 and 34,respectively, to limit the engagement of the plug with the roller. Fromthese figures the principle underlying the fluted plug body and thefunction thereof will be entirely apparent. The flutes provide a meansfor changing the overall length of the shade roller assembly, sincewhether the roller is initially too long or too short, by removing theterminal plug from the roller and rotating the plug, a different flutemay be selected for alignment with the seam in the roller tube, and whenthe plug is inserted into the roller to its fullest extent, the abutmentof the roller seam with the end wall of the selected flute provides asturdy assembly whose length is changed to correspond to that which isrequired.

Although the abutment between the end of the roller seam 48 and the endwalls (such as 22a or 34a) of the terminal plug flutes is firm andeasily sturdy enough to withstand all normal operating forces actingendwise of the roller assembly, it frequently happens in shipment andhandling that the entire roller assembly will be sharply dropped uponone of its ends, very often the gudgeon pin end. Generally speaking, asharp force such as this will usually be enough to drive a removableterminal plug substantially completely into the roller.

In the case of the present terminal plug construction, the outwardlyextending lugs 54 (FIGS. 1, 6, and 7) of the end portion 14 prevent anysuch occurrence, since they are generally coextensive with the outersurface of the shade roller and hence come into full abutment with theopen end thereof. However, if one of the flutes other than the longestone (i.e., flute 26) should be in alignment with the seam 48 in theroller tube when the roller is sharply dropped, the resulting forcecould be suflicient to drive the end wall of that particular flute pastthe end of the lock seam. Thus, the terminal plug itself could be drivenso far into the roller tube that the lugs 54 became flush with the endof the roller. If this should occur, the terminal plug would be tightlywedged into the roller and it would be difficult to extract ittherefrom, since only the gudgeon pin and the lugs themselves would thenprotrude from the roller and this would afford very little area to gripwhen extracting the plug.

The tabs 50 and 52 formed in the walls of the roller tube provide ameans for insuring that if the end walls of the flutes are driven insidethe roller tube, a desired length of the terminal plug will stillprotrude from the tube to enable the plug to easily be extracted. Inaccomplishing this, the tabs are positioned a distance from the open endof the roller which is less than the overall length of the terminalplug. This is illustrated in FIG. 6, where the tab 50 is seen placedimmediately behind the terminal plug with flute 22 almost fully engagedwith seam 48 in the roller. From this figure, it will be apparent thatif the terminal plug should be driven sharply into the roller, it couldonly move a slight amount before the rearward edge of the plug would beengaged by the tabs with the alignment between the tabs and the outersurface of the plug being seen in FIG. 5. Thus, substantially all of thelength of the plug seen protruding from the roller tube in FIG. 6 wouldremain outward of the plug, and this would allow the plug to be easilyextracted.

If any flute which is shorter than flute 22 should be engaged with theroller seam when the plug is driven inward of the roller, the end of theterminal plug would once again be engaged by the tabs 50 and 52 when theplug was driven into the tube an extent corresponding to the length offlute 22, as is illustrated in phantom in FIG. 7. Thus, the inwardmovement of the plug would again be arrested at the point where the plugremained protruding from the roller an amount corresponding to thelength which protrudes when flute 22 is fully engaged therewith.

In order to provide for the full engagement of flutes 24 and 26 with theroller tube, the portions 38, 40, 42 and 44 are cut away from the baseof the terminal plug in amounts corresponding to the amount that flutes24 and 26 exceed flute 22 in length. Thus, when flute 24 is in registerwith the seam 48, portions 38 and 42 will be in register with the tabs50 and 52 to prevent further insertion of the plug into the roller, andwhen flute 26 is in register with the seam, portions 40 and 44 will bein register with the tabs. Consequently, the plug may then be insertedinto the roller an amount exceeding that shown in FIG. 6, but the tabswill once again act to prevent the plug from being driven into theroller beyond the length of either of the two longest flutes.

From the foregoing explanation, it will be understood that the terminalplug provided by the present invention makes possible a quick, simple,and easy method of adjusting the overall length of a shade rollerassembly. No special tools, equipment, or skills are required to adjustthe roller length to the particular width of a given window. The deviceof the invention is extremely flexible in operation, and permits a Widerange of adjustments to be made in definite, known increments and at anytime subsequent to the original purchase and installation of the shaderoller. Further, the construction afforded by the invention overcomesthe problems which arise when the roller is dropped on its gudgeon pinend by providing a positive limit to the extent to which the terminalplug may be driven into the roller.

Having described the specific embodiment of the invention which is mostpreferred, it will be recognized that other embodiments and certainmodifications may be made which nonetheless embody the spirit of theinvention and incorporate its concepts. Consequently, all suchembodiments and modifications should be considered as included withinthe scope of the claims appended hereinafter, unless these claims bytheir language specifically state otherwise.

We claim:

1. An adjustable shade roller assembly, comprising: a shade rollerhaving an open tubular end; a removable terminal plug insertable intosaid roller end; means associated with one of said roller and terminalplug defining a stop structure; a plurality of recesses formed in theother one of said roller and terminal plug; each of said recessesdiffering in lengthwise extent from each other by predeterminedincremental amounts; each of said recesses arranged to be alignable withsaid stop structure to pass over the same; and each of said recesseshaving an end wall at its terminus for coming into abutting contact withsaid stop structure to limit the telescopic engagement of the plug withthe roller, whereby the overall length of said roller assembly may bevaried by realignment of said recesses and stop structure.

2. An adjustable shade roller assembly, comprising: a shade rollerhaving an open tubular end; means associated with said roller definingan internal stop structure; a removable terminal plug insertable intosaid roller end; said terminal plug having a plurality of recessesformed therein and extending lengthwise thereof from the end of the pluginserted into the roller end; said recesses differing in lengthwiseextent from each other by predetermined incremental amounts; each ofsaid recesses arranged to be alignable with said stop structure to passover the same; and each of said recesses having an end wall at itsterminus for coming into abutting contact with said stop structure tolimit the telescopic engagement of the plug with the roller, whereby theoverall length of said roller assembly may be varied by realignment ofsaid recesses and stop structure.

3. An adjustable shade roller assembly, comprising: a shade rollerhaving an open tubular end; said roller having an abutment stop on theinner surface of its tubular end portion; a removable terminal pluginserta'ble into said roller end; said terminal plug having a seriesofsurface grooves formed lengthwise thereof; said grooves each extendingfrom the end of said plug inserted into said roller and differing inlength by predetermined incremental amounts; each of said groovesarranged to be alignable with said abutment stop to pass over the samewhen the plug is inserted into the roller; and each of said groovesterminating in an end wall for coming into abutting contact with saidabutment stop to limit the telescopic engagement of the plug with theroller, whereby the overall length of said roller assembly may be variedby realignment of said grooves and abutment stop.

4. The roller assembly of claim 3, wherein said shade roller includes arolled sheet metal tube and said abutment stop is formed by alongitudinal seam in said tube.

5. The roller assembly of claim 3, wherein said terminal plug has acylindrical tubular body formed of resilient wall material; said tubularbody wall having a lap joint extending longitudinally thereof; and saidlap joint including circumferential-1y slidable interlocking meanspermitting limited diameter adjustment of the body; said plug normallyhaving a diameter larger than the inside of the roller tube and beingcontractable at said lap joint to inside the tube and expand outwardlyagainst it to provide a frictional engagement therebetween.

6. The roller assembly of claim 3, further including at least onesecondary stop means spaced from said abutment stop and further withinsaid tubular roller; said secondary stop means arranged to engageportions of the innermost end of said terminal plug in the event thesaid end walls are forcibly driven lbeyond said abutment stop, toprevent the terminal plug from being forced completely inside the rollertube.

7. The roller assembly of claim 6, wherein said shade roller includes arolled sheet metal tube and said secondary stop means are tabs struckfrom the walls of said tube and bent inwardly thereof.

8. As an article of manufacture, a terminal plug for a shade rollerhaving an open tubular end, said terminal plug comprising: a generallycylindrical body portion; a plurality of recesses formed in said bodyand extending lengthwise thereof from the end of the plug which isinserted into the roller end; said recesses differing in lengthwiseextent from each other by predetermined incremental amounts; and each ofsaid recesses having an end wall at its terminus.

9. As an article of manufacture, a terminal plug for a shade rollerhaving an open tubular end, said terminal plug comprising: a generallycylindrical body portion; a series of surface grooves formed lengthwiseof said body; said grooves each extending from the end of the plug whichis inserted into said roller and differing in length by predeterminedincremental amounts; and each of said grooves terminating in an endwall.

References Cited by the Examiner UNITED STATES PATENTS 1,175,345 3/1916Cunningham 160263 3,195,618 7/1965 Anderson et al 160323 FOREIGN PATENTS3,584 3/1890 Great Britain.

HARRISON R. MOSELEY, Primary Examiner.

P. M. CAUN, Assistant Examiner.

1. AN ADJUSTABLE SHADE ROLLER ASSEMBLY, COMPRISING: A SHADE ROLLERHAVING AN OPEN TUBULAR END; A REMOVABLE TERMINAL PLUG INSERTABLE INTOSAID ROLLER END; MEANS ASSOCIATED WITH ONE OF SAID ROLLER AND TERMINALPLUG DEFINING A STOP STRUCTURE; A PLURALITY OF RECESSES FORMED IN THEOTHER ONE OF SAID ROLLER AND TERMINAL PLUG; EACH OF SAID RECESSESDIFFERING IN LENGTHWISE EXTEND FROM EACH OTHER BY PREDETERMINEDINCREMENTAL AMOUNTS; EACH OF SAID RECESSES ARRANGED TO BE ALIGNABLE WITHSAID STOP STRUCTURE TO PASS OVER THE SAME; AND EACH OF SAID RECESSESHAVING AN END WALL AT ITS TERMINUS FOR COMING INTO ABUTTING CONTACT WITHSAID STOP STRUCTURE TO LIMIT THE TELESCOPIC ENGAGEMENT OF THE PLUG WITHTHE ROLLER, WHEREBY THE OVERALL LENGTH OF SAID ROLLER ASSEMBLY MAY BEVARIED BY REALIGNMENT OF SAID RECESS AND STOP STRUCTURE.